3.

ENERGY PERFORMANCE ASSESSMENT OF

COGENERATION SYSTEMS WITH STEAM AND GAS
TURBINES
3.1 Introduction
Cogeneration systems can be broadly classified as those using steam turbines, Gas
turbines and DG sets. Steam turbine cogeneration systems involve different types of
configurations with respect to mode of power generation such as extraction, back
pressure or a combination of backpressure, extraction and condensing.

Gas turbines with heat recovery steam generators is another mode of cogeneration.
Depending on power and steam load variations in the plant the entire system is dynamic.
A performance assessment would yield valuable insights into cogeneration system
performance and need for further optimization.

3.2 Purpose of the Performance Test

The purpose of the cogeneration plant performance test is to determine the power output
and plant heat rate. In certain cases, the efficiency of individual components like steam
turbine is addressed specifically where performance deterioration is suspected. In general,
the plant performance will be compared with the base line values arrived at for the plant
operating condition rather than the design values. The other purpose of the performance
test is to show the maintenance accomplishment after a major overhaul. In some cases the
purpose of evaluation could even be for a total plant revamp.

3.3 Performance Terms and Definitions

Overall Plant Performance

1. Overall plant heat rate, kCal/kWh

Mass flow rate of steam x ( Enthalpy of steam, kCal / kg − Enthalpy of feed water , kCal / kg )
=
Power output , kW

Fuel consumption* in kg/hr

2. Overall plant fuel rate kg/kWh =
Power output,kW
*Total fuel consumption for turbine and steam

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Steam Turbine Performance

Actual enthalpy drop across the turbine, kCal / kg

Turbine cylinder efficiency, % = x 100
Isentropic (theoritical ) enthalpy drop across the turbine, kCal / kg

Gas Turbine Performance

Theoritical temperature rise across the compressor , oC

Air compressor efficiency, % = x 100
Actual temperature rise, oC

Overall Gas turbine efficiency

Power output , kW x 860
(Compressor + Gas turbine), % = x 100
Fuel input for Gas Turbine, kg / hr x GCV of fuel , kCal / kg

Heat Recovery Steam Generator (HRSG) Performance

Heat Recovery Steam Generator efficiency, %

Steam generated , kg / hr x (hs , kCal / kg − hw , kCal / kg )

=
[ Mass flow of flue gas, kg / hr x C p x (tin − tout )] + [auxiliary fuel consumption, kg / hr x GCV of fuel , kCal / kg ]

where, hs = Enthalpy of steam

hw = Enthalpy of feed water
tin = inlet temperature of flue gas
tout = outlet temperature of flue gas

3.4 Reference standards

Modern power station practices by British electricity International (Pergamon Press)
ASME PTC 22 – Gas turbine performance test.

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3.5 Field Testing Procedure

The test procedure for each cogeneration plant will be developed individually taking into
consideration the plant configuration, instrumentation and plant operating conditions. A
method is outlined in the following section for the measurement of heat rate and
efficiency of a co-generation plant. This part provides performance-testing procedure for
a coal fired steam based co-generation plant, which is common in Indian industries.

3.5.1 Test Duration

The test duration is site specific and in a continuous process industry, 8-hour test data
should give reasonably reliable data. In case of an industry with fluctuating
electrical/steam load profile a set 24-hour data sampling for a representative period.

3.5.2 Measurements and Data Collection

The suggested instrumentation (online/ field instruments) for the performance
measurement is as under:

Steam flow measurement : Orifice flow meters

Fuel flow measurements : Volumetric measurements / Mass flow meters
Air flow / Flue gas flow : Venturi / Orifice flow meter / Ion gun / Pitot tubes
Flue gas Analysis : Zirconium Probe Oxygen analyser
Unburnt Analysis : Gravimetric Analysis
Temperature : Thermocouple
Cooling water flow : Orifice flow meter / weir /channel flow/
non-contact flow meters
Pressure : Bourdon Pressure Gauges
Power : Trivector meter / Energy meter
Condensate : Orifice flow meter

It is essential to ensure that the data is collected during steady state plant running
conditions. Among others the following are essential details to be collected for
cogeneration plant performance evaluation.

I. Thermal Energy :

Flow Pressure Temperature

1 Steam inlet to turbine a a a
Fuel input to Boiler /Gas
2
turbine a - -
3 Combustion air a a a
Extraction steam to process
4 a a a
Back Pressure Steam to
5
Process a a a
6 Condensing steam a a a
7 Condensate from turbine a - a
8 Turbine bypass steam a - -

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 3. Energy Performance Assessment of Cogeneration Systems

9 Flue gas to HRSG - a a

10 Exit flue gas - - a+ composition
11 Cooling water to condenser a a a
II. Electrical Energy:

1. Total power generation for the trial period from individual turbines.
2. Hourly average power generation
3. Quantity of power import from utility ( Grid )*
4. Quantity of power generation from DG sets.*
5. Auxiliaries power consumption

* Necessary only when overall cogeneration plant adequacy and system optimization
/ upgradation are the objectives of the study.

3.5.3 Calculations for Steam Turbine Cogeneration System

The process flow diagram for cogeneration plant is shown in figure 3.1. The following
calculation procedures have been provided in this section.

• Turbine cylinder efficiency.

• Overall plant heat rate

h1

h11
Boiler

Extraction cum
S

condensing
Turbine Power output
h11 kW

Boiler h2 H1
1st Extraction
h3 H2 h4 H3
2st Extraction

Condenser

Figure 3.1 Process Flow Diagram for Cogeneration Plant

Step 1 :

Calculate the actual heat extraction in turbine at each stage,

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 3. Energy Performance Assessment of Cogeneration Systems

Steam Enthalpy at turbine inlet : h1 kCal / kg

Steam Enthalpy at 1st extraction : h2 kCal / kg
Steam Enthalpy at 2nd extraction : h3 kCal / kg
Steam Enthalpy at Condenser : h4* kCal / kg

* Due to wetness of steam in the condensing stage, the enthalpy of steam cannot be
considered as equivalent to saturated steam. Typical dryness value is 0.88 – 0.92. This
dryness value can be used as first approximation to estimate heat drop in the last stage.
However it is suggested to calculate the last stage efficiency from the overall turbine
efficiency and other stage efficiencies.
Heat extraction from inlet : h1 – h2 kCal / kg
to stage –1 extraction (h5)

Heat extraction from : h2-h3 kCal / kg

1st –2nd extraction (h6)

Heat extraction from 2nd : h3-h4 kCal / kg

Extraction – condenser (h7)
Step 2:
From Mollier diagram (H-φ Diagram) estimate the theoretical heat extraction for the
conditions mentioned in Step 1. Towards this:
a) Plot the turbine inlet condition point in the Mollier chart – corresponding to
steam pressure and temperature.

b) Since expansion in turbine is an adiabatic process, the entropy is constant.

Hence draw a vertical line from inlet point (parallel to y-axis) upto the
condensing conditions.

c) Read the enthalpy at points where the extraction and condensing pressure lines
meet the vertical line drawn.

d) Compute the theoretical heat drop for different stages of expansion.

Theoretical Enthalpy after 1st extraction : H1

Theoretical Enthalpy after 2nd extraction : H2
Theoretical Enthalpy at condenser conditions : H3

Theoretical heat extraction from inlet to : h1 – H1

stage 1 extraction, h8

Theoretical heat extraction from : H1-H2

1st – 2nd extraction, h9

Theoretical heat extraction from : H2-H3

2nd extraction – condensation, h10

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 3. Energy Performance Assessment of Cogeneration Systems

Step 3 :
Compute turbine cylinder efficiency

⎛h ⎞ Heat extraction actual h −h

Efficiency of 1st stage ⎜⎜ 5 ⎟⎟ = = 1 2
⎝ h8 ⎠ Heat extraction theoritical h1 − H1

⎛h ⎞ Heat extraction actual h −h

Efficiency of 2 nd stage ⎜⎜ 6 ⎟⎟ = = 2 3
⎝ h9 ⎠ Heat extraction theoritical H1 − H 2

Efficiency of condensing stage : h7

h10
Step 4 :
Calculate plant heat rate*

M x (h1 − h11 )
Heat rate, kCal/kWh =
P

M – Mass flow rate of steam in kg/hr

h1 - Enthalpy of inlet steam in kCal/kg
h11 - Enthalpy of feed water in kCal/kg
P - Average Power generated in kW

*Alternatively the following guiding parameter can be utilised

Plant heat consumption = fuel consumed for power generation, kg/hr

Power generated, kW
3.6 Example
3.6.1 Small Cogeneration Plant

A distillery plant having an average production of 40 kilolitres of ethanol is having a

cogeneration system with a backpressure turbine. The plant steam and electrical demand
are 5.1 Tons/hr and 100 kW. The process flow diagram is shown in figure 3.2.Gross
calorific value of Indian coal is 4000kCal/kg

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Steam to turbine
Q – 5100 kg/hr
P – 15 kg/cm 2 g Back
T – 250 o C Pressure

S
Boiler
Coal Turbine
1550 kg/hr Power output
100kW

Process Steam
Q – 5100 kg/hr
P – 2 kg/cm 2 g
T – 130 o C

Figure 3.2 Process Flow Diagram for Small Cogeneration Plant

Calculations :

Step 1 :

Total heat of steam at turbine inlet conditions at 15kg / cm2 and 250oC, h1 =698kCal/kg

Step 2 :

Total heat of steam at turbine outlet conditions at 2 kg/cm2 and 130oC, h2 = 648 kCal/kg

Step 3 :

Heat energy input to turbine per kg of inlet steam (h1- h2) = (698-648) = 50 kCal/kg

Step 4 :

Total steam flow rate, Q1 = 5100 kg/hr

Power generation = 100 kW
Equivalent thermal energy = 100 x 860 = 86,000 kCal /hr

Step 5 :

Energy input to the turbine = 5100 x 50 = 2,55,000 kCal/hr.

Step 6 :

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Energy output
Power generation efficiency of the turbo alternator = x 100
Energy input

86,000
= ------------- x 100 = 34%
2,55,000
Step 7 :
Efficiency of the turbo alternator = 34%
Efficiency of Alternator = 92 %
Efficiency of gear transmission = 98 %

Power generation efficiency of turbo alternator

EfficiencyofTurbine =
Efficiency of gear transmission * Efficiency of Alternator

0.34
= = 0.38
0.98 * 0.92
Step 8 :

Quantity of steam bypassing the turbine = Nil

Step 9 :

Coal consumption of the boiler = 1550 kg/hr.

Step 10:

Overall plant heat rate, kCal/kWh

= Mass flow rate of steam x ((Enthalpy of steam, kCal/kg – Enthalpy of feed water,kCal/kg)
Power output, kW
= 5100 x (698 – 30)
100

= 34068 kCal/kWh*

*Note: The plant heat rate is in the order of 34000 kCal/kWh because of the use of
backpressure turbine. This value will be around 3000 kcal/kWh while operating on fully
condensing mode. However with backpressure turbine, the energy in the steam is not
wasted, as it is utilised in the process.

Overall plant fuel rate including boiler = 1550/100

= 15.5 kg coal / kW

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 3. Energy Performance Assessment of Cogeneration Systems

Analysis of Results:

The efficiency of the turbine generator set is as per manufacturer design specification.
There is no steam bypass indicating that the power generation potential of process steam
is fully utilized. At present the power generation from the process steam completely
meets the process electrical demand or in other words, the system is balanced.

Remarks: Similar steps can be followed for the evaluation of performance of gas turbine
based cogeneration system.

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 3. Energy Performance Assessment of Cogeneration Systems

QUESTIONS

1. What is meant by plant heat rate? What is its significance?

2. What is meant by turbine cylinder efficiency? How is it different from turbo-
generator efficiency?
3. What parameters should be monitored for evaluating the efficiency of the turbine?
4. What is the need for performance assessment of a cogeneration plant?
5. The parameters for back pressure steam turbine cogeneration plant is given below
2 o
Inlet Steam: P =16 kg/cm , T = 310 C , Q = 9000kg/hr
2 o
Outlet Steam: P = 5.0 kg/cm , T = 235 C , Q = 9000kg/hr
Find out the turbine cylinder efficiency?

6. Explain why heat rate for back pressure turbine is greater than condensing turbine.
7. Explain the methodology of evaluating performance of a gas turbine with a heat
recovery steam generator.

REFERENCES

1. NPC report on ‘Assessing cogeneration potential in Indian Industries’

2. Energy Cogeneration Handbook, George Polimeros, Industrial Press Inc.

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